Please note: I scanned and typed most of this stuff, I think
it is pretty accurate. I double checked most of the figures and tried to
concentrate on the numbers. If you find an error or would like me to check
the manual just e-mail me. Some
of the listings in the manual were incorrect and I tried to correct them
as I went. Keep all this in mind and use this
information at your own risk.
General Specifications (back
to Index)
1978 | 1979 | |
Model: (back to Index)
I.B.M. No. Frame I.D. and starting number Engine I.D. and starting number |
2J2 2J2-000101 2J2-000101 |
2J2-020101
2J2-020101 |
Dimensions: (back to Index)
Overall length Overall width (standard) Overall heigth (standard) Wheel base Minimum ground clearance |
2,105 mm (82.9 in) 835 mm (32.9 in) 1,150 mm (45.3 in) 1,410 mm (55.5 in) 165 mm (6.5 in) |
|
Weight: (back to Index)
Net weight |
163 kg (359 lbs) |
|
Performance: (back to
Index)
Climbing ability Minimum turning radius Braking distance |
30 deg 2,400 mm (94.5 in) 14 m (45.9 ft) at 50km/h (31 mph) |
Engine specifications (back
to Index)
Description: (back to
Index)
Engine type Engine model Displacement Bore x Stroke Compression Ratio Starting system Ignition system Lubrication system |
Air cooled 4-stroke, foward incline, single, S.O.H.C. 2J2 499 cc (30.45 cu. in.) 87 x 84 mm (3.425 x 3.307 in) 9.0 : 1 Primary kick starter C.D.I. Dry Sump system |
Cylinder Head: (back
to Index)
Combustion chamber type Combustion chamber volume (with BP7ES or N-7Y) Head gasket thickness |
Dome 62.4 cc (3.81 cu. in.)
|
Camshaft: (back to Index)
Cam drive type Camshaft bearing type (left) Camshaft bearing type (right) Cam chain type and No. of links |
Drive chain (right side drive) 6005C3 6005C3 (with groove) BF05M, 106L |
Cam dimensions: (back to Index) A (Cam Heigth) IN. A (Cam Heigth) EX. B (Base circle) IN. B (Base circle) EX. C (Cam lift) IN.
|
required <allowable>
BTDC 44 deg
|
Rocker arm and rocker shaft:(Index)
Rocker arm bearing dia. (I.D.) Rocker arm shaft dia. (O.D.) Clearance |
required <allowable>
12.00~12.02 mm <12.05 mm> (.4724~.4732 in <.4744 in>) 11.98~11.99 mm <11.96 mm> (.4714~.4720 in <.4709 in>) .01~.04 mm <.11 mm> (.0004~.0016 in <.0043 in>) |
Valve, valve seat and valve guide:(Index)
Valve clearance (cold): IN. Valve clearance (cold): EX. No. of valves per cylinder: Valve head dia. (A): IN. Valve head dia. (A): EX. Valve face width (B): IN. Valve face width (B): EX. Valve seat width (C): IN. Valve seat width (C): EX. Valve margin thickness (D): IN. Valve margin thickness (D): EX. Valve stem outside dia.: IN. Valve stem outside dia.: EX. Valve guide inside dia.: IN. Valve guide inside dia.: EX. Valve stem to guide clearance: IN. Valve stem to guide clearance: EX. |
required <allowable>
.10 mm (.0039 in) .15 mm (.0059 in) 2 pcs 47 mm (1.85 in)
|
Valve springs: (back
to Index)
Free length: Inner Free length: Outer Spring rate: Inner Spring rate: Outer Installed length (valve closed): Inner
|
required <allowable>
45.3 mm <43.9 mm> (1.783 in <1.728 in>) 44.6 mm <43.3 mm> (1.756 in <1.703 in>) K1= 1.67, K2 = 2.12 [kg/mm] (K1 = 93.5, K2 = 119 [lb/in]) K1 = 3.60, K2 - 4.63 [kg/mm] (K1 = 202, K2 = 259 [Ib/in]) 38.0 mm (1.496 in) 40.0 mm (1.575 in) 12.2 kg (26.9 Ib) 16.4 kg (36.2 Ib) 28.0 mm (1.102 in) 30.0 mm (1.181 in) 33.4 kg (73.6 Ib) 62.7 kg (138.2 lb) 3.1 mm (.122 in) 4.4 mm (0.173 in) 23.4 mm (.921 in) 32.9 mm (1.295 in) 1.97 mm (.0776 in) 1.97 mm (.0776 in) |
Cylinder: (back to Index)
Material Bore size Taper limit
|
required <allowable>
Aluminum alloy with special cast iron sleeve 87.00 ~87.02 mm <87.1 mm> (3.4252 ~3.4260 in <3.429 in>) <.05 mm> (<.0020 in>) <.01 mm> (<.0004 in>) |
Piston: (back to Index)
Piston clearance Piston clearance measuring position (from piston skirt bottom) Piston pin bore size Piston pin outside diameter Piston pin length
|
required <allowable>
.050 ~ .055 mm (.0020 ~ .0022 in) 7.2 mm (.283 in)
|
Piston ring: (back to
Index)
Piston ring design: Top ring Piston ring design: 2nd ring Piston ring design: Oil ring Ring end gap (installed): Top ring Ring end gap (installed): 2nd ring Ring end gap (installed): Oil ring
Ring groove side clearance: 2nd ring Ring groove side clearance: Oil ring
|
required <allowable>
Plain ring Plain ring Oil ring with expander .3 ~ .5 mm <0.8 mm> (.012 ~ .020 in <.030 in>) .3 ~ .5 mm <.8 mm> (.012 ~ .020 in <.031 in>) .2 ~ .9 mm <1.0 mm> .04 ~ .08 mm <.15 mm> (.0016 ~ .0031 in <.0059 in>) .03 ~ .07 mm <.15 mm> (.0012 ~ .0028 in <.0059 in>) N.A. 87.25 mm (3.4350 in) 87.50 mm (3.4449 in) 87.75 mm (3.4547 in) 88.00 mm (3.4646 in) |
Big end bearing: (back to
Index)
Type Inside dia. x outside dia. x width Needle dia. x quality |
Needle bearing 34 x 42 x 24 mm (1.34 x 1.65 x .94 in) IKO 4 mm (.16 in) x 18 pcs KOYO 4 mm (.16 in) x 17 pcs. |
Crankshaft: (back to Index)
Crankshaft assembly width (F) Crankshaft deflection ( D ) Connecting rod large end side clearance (C) Connecting rod small end deflection (P) Crank pin outside dia. x length Crank bearing type; Left Crank bearing type; Right Crank oil seal type: Left Crank oil seal type: Right |
required <allowable>
74.95 ~ 75.00 mm (2.9508 ~ 2.9528 in) <.03 mm (.0012 in) or less> .35 ~ .65 mm (.0138 ~ .0256 in) .8 ~ 1.0 mm <2.0 mm> (.0315 ~ .0394 in <0.079 in>) 34 x 74 mm (1.34 x 2.91 in)
|
Clutch: (back to Index)
Clutch type Clutch push mechanism Primary reduction ratio and method Primary reduction gear back lash number Primary drive gear back lash number Primary driven gear back lash number Friction plate: Thickness/quantity Clutch plate: Thickness/quantity
Clutch spring: Spring set weight
|
required <allowable>
Wet, multiple disc type Inner push, cam axle type 77/30 (2.566), spur gear 148 ~ 150 21.79 +0 -.04 mm (4 Teeth) 52.71 +0 -.04 mm (9 Teeth) 2.8 mm <2.5 mm> /8 pcs. (.110 in <.098 in> /8 pcs.) 1.2 mm /7 pcs. (.047 in /7 pcs.) <.05 mm (.0020 in)> 41.2 mm <40.0 mm> /6 pcs. (1.622 in <1.575 in> /6 pcs.) 19.8 x 6 kg/25 mm (43.7 6 lb/.984 in) 1.22 kg/mm (68.3 lb/in) .10 ~ .21 mm (.004 ~ .008 in) <.2 mm (.0079 in) or less> Needle bearing (17-21.5-15) x 2 pcs. SD-17-28-6 |
Transmission: (back
to Index)
Type Gear ratio: 1st Gear ratio: 2nd Gear ratio: 3rd Gear ratio: 4th Gear ratio: 5th Bearing type: Main axle (Left) Bearing type: Main axle (Right) Drive axle (Left) Drive axle (Right) Drive axle (Left) Secondary reduction ratio and method |
Constant mesh. 5 speed 33/14 (2.357) 28/18 (1.555) 25/21(1.190) 22/24 (0.916) 21/27 (0.777) Needle bearing (20-32-12) 4205 6305 special Needle bearing (20-36-12) SD-35-62-10 44/16 (2.750), chain |
Shifting mechanism: (back
to Index)
Operation system Shifting type Oil seal type: Change lever |
Return type, left foot operation Guide bar type, cam drum system SDO-14-24-6 |
Kick starter: (back
to Index)
Type Oil seal type Kick axle |
Ratchet type SD-25-35-7 |
Compression releaser: (back
to Index)
Type Lever free play Oil seal type |
Manual, wire linked cam axle type 2 mm (.079 in) SD-12-17-2.5-2NR |
Air cleaner: (back to
Index)
Type/quantity |
Dry foam rubber / l pc. |
Carburetor: (back to Index)
Type and manufacture/quantity I I.D. mark Main jet (M.J.) Airjet (A.J.) Jet needle: Clip position (J.N.) Needle jet (N.J.) Cutaway (C.A.) Pilot jet (P.J.) Mixture screw turns out Starter jet(G.S.) Float hight Idling engine speed |
VM34SS MIKUNI / I pc. 2J200 #300 #80 6FL25-2 P-8 3.5 #25 Preset #50 23.5 +or- 1 mm (.925 +or- .039 in) 1100 r/min |
Lubrication: (back to
Index)
Transmission gear and engine sump oil Quantity Type engine oil
Oil pump: Housing depth (delivery) Oil pump: Housing depth (scavenger) Oil pump: Rotor diameter Oil pump: Rotor thickness (delivery)
Side clearance Tip clearance Check valve opening pressure
|
required <allowable>
Total amount: 2.4 lit (2.5 US.qt)(2.11 IMP.qt) Periodic oil charge: 2.0 lit (2.1 US.qt)(1.76 IMP.qt) Exchange with oil fjlter: 2.1 lit (2.2 US.qt)(1.85 IMP.qt) Yamalube 20W / 40 motor oil or equivalent Trochoid pump 40.65 ~ 40.68 mm <40.85> (1.6004 ~ 1.6016 <1.6083 in>) 4.03 ~ 4.06 mm <4.09 mm> (.1587 ~ .1598 in <.1610 in>) 18.03 ~ 18.06 mm <18.09 mm> (.7098 ~ .7118 in <0.7122 in>) 40.53 ~ 40.56 mm <40.50 m> (1.5957 ~ 1.5968 in <1.5945 in>) 3.98 ~ 4.00 mm <3.95 mm> (.1567 ~ .1575 in <.1555 in>) 17.98 ~ 18.00 mm <17.95 mm>) .09 ~ .15 mm <.35 mm> (.0035 ~ .0059 in <.0138 in>) .03 ~ .08 mm <0.14 mm> (.0012 ~ .0031 in <.0055 in>) .07 ~ .12 mm <.35 mm> (.0028 ~ .0047 in <.00138 in>) .18 kg/cm2 (2.56 lb/in2) 1.0 kg/cm2 (14.2 lb/in2) Paper type |
Chassis specification (back
to Index)
Frame: (back to Index)
Frame design |
Tubular steel semi double cradle |
Steering system: (back
to Index)
Caster Trail Number and size of balls in steering head: Upper race Lower race Lock to lock angle |
27.5 deg (62.5 deg) 117 mm (4.6 in) 22 pcs. 3/16 in
|
Front suspension: (back
to Index)
Type Front fork cushion travel Front fork spring:
Inner tube outside diameter
|
Telescopic forks 150 mm (5.9 in) 445 mm (17.52 in)
|
Rear suspension: (back to Index)
Type Damper type Rear shock absorber travel Rear wheel travel Rear shock absorber spring: Free length Set length (soft position) Wire dia. x winding dia. Spring constant Swing arm free play (limit)
|
required <allowable>
Swing arm Coil spring, oil damper 80 mm (3.15 in) 110 mm (4.33 in) 216.5 mm (8.52 in)
|
Fuel tank: (back to Index)
Capacity Fuel grade |
12 lit (3.2 US.Gal)(2.6 IMP.gal) Regular gasoline |
Wheel: (back to Index)
Type Tire size and pattern: Front Tire size and pattern: Rear Rim type: Front Rim type: Rear Rim runout (limit): Front/Rear Rim hopping (limit): Front/Rear Bearing type: (back to Index) Front wheel (Left) Front wheel (Right) Rear wheel (Left) Rear wheel (Right) Oil seat type: Front wheel ( Left) Front wheel (Right) Meter gear Rear wheel (Left) Rear wheel (Right) Secondary drive chain: (back to Index) Type Number of links Chain pitch Chain free play |
required <allowable>
Casting wheel 3.50-S19-4PR. lug type 4.00-S18-4PR. lug type 1.85-19 / Aluminum 2.15-18 / Aluminum <2 mm> (<.08 in>) <2 mm> (<.08 in>) 6303ZZ
..................
DID 50 HDSS
|
Brake (Front and rear): (back
to Index)
Type Disc size (Outside die. thickness) Front Rear Disc wear/limit Disc pad thickness Pad wear limit (Minimum thickness) Master cylinder inside dia. Caliper cylinder inside dia. Brake fluid type |
required <allowable>
Hydraulic disc type 298 x 5 mm (11.73 x .02 in)
|
Electrical Specifications (back
to Index)
Voltage (back to Index) | 12V |
Ignition system: (back
to Index)
C.D.I. Model/Manufacturer Pulser coil resistance High speed (White/Red-Black) Low speed (White/Green-Black) Charge coil resistance High speed (Red-Brown) Low speed (Brown-Black) Ignition timing: Ignition advancer: Advance type Advance angle Advance starting engine speed Full advance engine speed Ignition coil: (back to Index) Model/manufacturer Spark gap Primary winding resistance Secondary winding resistance Spark plug: (back to Index) Type Spark plug gap C. D.I. unit: Model/Manufacturer |
required <allowable>
032000-045 / NIPPON DENSO 16 ohm +or- 30% at 20 deg C(68 deg F)
334 ohm +or- 30% at 20degC(68 deg F)
Electrical
029700-468 / NIPPON DENSO
BP-7ES (N.G.K.) or N- 7Y (CHAMPION)
070000-035/NIPPON DENSO |
Charging system: (back to
Index)
AC. magneto: Model/Manufacturer Rotor puller thread size Output Stater coil resistance White-Yellow White-White Rectifier with regulator: (back to Index) Model/Manufacturer (Rectifier) Type Capacity Withstand voltage (Regulator) Type Regulating voltage Allowable amperage Battery: (back to Index) Model/Manufacturer Capacity Charging rate Specific gravity |
032000-045 / NIPPON DENSO
M27 x P 1.0 14.5V-11A / 5000 r/min .73 ohm +or- 30% at 20 deg C (68 deg F)
SH235 / SHINDENGEN I.C. type. three phase full wave
I.C. type
12N7-3B / G.S.
|
Lighting system: (back to
Index)
Headlight type: Bulb wattage/Quantity: Headlight Taillight Brake light Flasher light Turn indicator light Meter light High beam indicator light Neutral indicator light |
Sealed beam 12V, 50W/40W x 1
|
Horn: (back to Index)
Model/Manufacturer Winding resistance Amperage Flasher relay: (back to Index) Type Model/Manufacturer Flasher frequency Capacity |
CF-12 / NIKKO HORN 1.24 ohm +or- 10% at 20 deg C (68 deg F) 2.5A Condenser type
|
Fuse:
Rating |
20A |
Torque specifications (back
to Index)
Standard (back to Index)
Nut size | Shaft size | Standard
Torque m-kg |
Standard
Torgue ft-lb |
10 mm | 6 mm | 1.0 | 7 |
12 mm | 8 mm | 2.0 | 14.5 |
14 mm | 10 mm | 4.0 | 29 |
17 mm | 12 mm | 4.5 | 33 |
19 mm | 14 mm | 5.0 | 36 |
22 mm | 16 mm | 6.5 | 47 |
24 mm | 18 mm | 7.0 | 50 |
27 mm | 20 mm | 8.0 | 58 |
Part to be tightened | Thread dia. and part name | Tightening torque |
Engine: (back
to Index)
tightening sequence for head bolts |
1~5 (10mm nuts)
6, 7 &10 (8mm nuts) 8, 9, 11 &12 (6mm bolts) |
3.8 m-kg (27.5 ft-lb)
2.0 m-kg (14.5 ft-lb) 1.0 m-kg ( 7.0 ft-lb) |
Cylinder head and cylinder head cover
Cylinder head
Cylinder head cover
Flywheel
Delivery pipe
Crankcase 1 and 2
|
10 mm stud bolt
10 mm nut 8 mm stud bolt 8 mm nut 10 mm stud bolt 10 mm nut 6 mm bolt 6 mm bolt 6 mm bolt 14 mm 10 mm stud bolt 10 mm nut 6 mm bolt 12 mm nut 6 mm pan head screw 8 mm nut 10 mm bolt 18 mm nut 30 mm cap 6 mm pan head screw 6 mm bolt 14 mm bolt 6 mm bolt 5 mm bleeder screw 8 mm union bolt 14 mm union nut 8 mm stud bolt 8 mm nut 6 mm bolt 8 mm bolt 6 mm screw 16 mm nut 18 mm nut 18 mm nut 6 mm bolt |
2.0 m-kg (14.5 ft-lb)
3.8 m-kg (27.5 ft-lb) 1.3 m-kg ( 9.5 ft-lb) 2.0 m-kg (14.5 ft-lb) 2.0 m-kg (14.5 ft-lb) 3.8 m-kg (27.5 ft-lb) 1.0 m-kg ( 7.0 ft-lb) 1.0 m-kg ( 7.0 ft-lb) 1.0 m-kg ( 7.0 ft-lb) 2.0 m-kg (14.5 ft-lb) 2.0 m-kg (14.5 ft-lb) 3.8 m-kg (27.5 ft-lb) 1.0 m-kg ( 7.0 ft-lb) 8.0 m-kg (58.0 ft-lb) 0.9 m-kg ( 6.5 ft-lb) 2.7 m-kg (19.5 ft-lb) 5.0 m-kg (36.0 ft-lb) 4.0 m-kg (29.0 ft-lb) 2.0 m-kg (14.5 ft-lb) 0.7 m-kg ( 5.0 ft-lb) 1.0 m-kg ( 7.0 ft-lb) 3.0 m-kg (21.5 ft-lb) 1.0 m-kg (7.0 ft-lb) 0.5 m kg (3.5 ft-lb) 1.8 m-kg (13.0 ft-lb) 4.0 m-kg (29.0 ft-lb) 1.3 m-kg ( 9.5 ft-lb) 1.8 m-kg (13.0 ft-lb) 1.0 m-kg ( 7.0 ft-lb) 2.0 m-kg (14.5 ft-lb) 0.8 m-kg ( 6.0 ft-lb) 6.0 m-kg (43.5 ft-lb) 6.0 m-kg (43.5 ft-lb) 7.0 m-kg (50.5 ft-lb) 0.8 m-kg (6.0 ft-lb) |
Chassis: (back
to Index)
Engine mounting bolt Handle crown and steering shaft
|
10 mm nut 8 mm nut 14 mm nut 8 mm bolt 8 mm nut 30 mm bolt
|
5.0 m-kg (36.0 ft-lb) 2.5 m-kg (18.0 ft-lb) 5.5 m-kg (40.0 ft-lb) 2.0 m-kg (14.5 ft-lb) 1.5 m-kg (11.0 ft-lb) 2.5 m-kg (18.0 ft-lb)
|
Disc brake: (back
to Index)
Brake disc and hub (Front) Caliper bracket and front fork (Front) Caliper and brake hose (Front) Caliper and bleed screw (Front) Master cylinder and brake hose (Front) Brake hose 1 and joint (Front) Brake disc and hub (Rear)
|
8 mm bolt 10 mm bolt 10 mm bolt 8 mm bolt 10 mm bolt 10 mm bolt 8 mm bolt
|
2.0 m-kg (14.5 ft-lb) 3.5 m-kg (25.5 ft-lb) 2.5 m-kg (18.0 ft-lb) 0.6 m-kg ( 4.5 ft-lb) 2.5 m-kg (18.0 ft-lb) 2.5 m-kg (18.0 ft-lb) 2.0 m-kg (14.5 ft-lb)
|